A stator for an electric motor and a method of manufacturing a stator

ABSTRACT

A stator for an electric motor, the stator comprising a back-iron having a first surface and a heat sink having a second surface, wherein the first surface of the back-iron includes a plurality of keying features arranged to retain the heat sink to the back-iron, wherein the heat sink is arranged to provide cooling to the back-iron via the second surface, and wherein the second surface has complementary keying features to the plurality of keying features on the first surface that are formed by casting the heat sink on the first surface of the back-iron.

The present invention relates to a stator for an electric motor and a method of manufacturing a stator for an electric motor.

With increased interest being placed in environmentally friendly vehicles there has been a corresponding increase in interest in the use of electric motors for providing drive torque for electric vehicles.

Electric motors work on the principle that a current carrying wire will experience a force when in the presence of a magnetic field. When the current carrying wire is placed perpendicular to the magnetic field the force on the current carrying wire is proportional to the flux density of the magnetic field. Typically, in an electric motor the force on a current carrying wire is formed as a rotational torque.

Examples of known types of electric motor include the induction motor, brushless permanent magnet motor, switched reluctance motor and synchronous slip ring motor, which have a rotor and a stator, as is well known to a person skilled in the art.

In the commercial arena three phase electric motors are the most common kind of electric motor available.

A three phase electric motor typically includes three coil sets, where each coil set is arranged to generate a magnetic field associated with one of the three phases of an alternating voltage.

To increase the number of magnetic poles formed within an electric motor, each coil set will typically have a number of coil sub-sets that are distributed around the periphery of the electric motor, which are driven to produce a rotating magnetic field.

The three coil sets of a three phase electric motor are typically configured in either a delta or wye configuration. The current flow through the coil windings will generate heat, which can result in a reduction in efficiency and power generating capabilities of an electric motor, where effective cooling is essential for high continuous torque.

The current flow through the coil windings is typically controlled via a control unit, where for a three phase electric motor having a DC power supply, the control unit will typically include a three phase bridge inverter that generates a three phase voltage supply for driving the electric motor. Each of the respective voltage phases is applied to a respective coil set of the electric motor.

Typically, the three phase bridge inverter will generate a three phase voltage supply using a form of pulse width modulation (PWM) voltage control. PWM control works by using the motor inductance to average out an applied pulse voltage to drive the required current into the motor coils. Using PWM control an applied voltage is switched across the motor coils. During this on period, the current rises in the motor coils at a rate dictated by its inductance and the applied voltage. The PWM control is then required to switch off before the current has changed too much so that precise control of the current is achieved.

A three phase bridge inverter includes a number of switching devices, for example power electronic switches such as Insulated Gate Bipolar Transistor (IGBT) switches.

In the context of an electric vehicle motor, a drive design that is becoming increasing popular is an integrated in-wheel electric motor design in which an electric motor and its associated control system are integrated within a wheel of a vehicle.

However, the integration of an electric motor, and its associated control system, within a wheel of a vehicle can impose increased thermal management considerations upon the electric motor, which can additionally result in a reduction in efficiency and power generating capabilities of an electric motor.

In accordance with an aspect of the present invention there is provided a stator and a method of manufacturing a stator according to the accompanying claims.

The invention as claimed provides the advantage of improving the retention of a stator back-iron to a heat sink, thereby improving the structural integrity of the electric motor, while also increasing the surface area of the interface between the stator back-iron and the heat sink to allow the thermal interface between these two components to be improved, thereby improving heat transfer from the stator back-iron to the heat sink by improving the thermal conductivity across the interface between the back-iron and the heat sink.

The present invention will now be described, by way of example, with reference to the accompanying drawings, in which:

FIG. 1 illustrates an exploded view of a motor embodying the present invention;

FIG. 2 is an exploded view of the motor of FIG. 1 from an alternative angle;

FIG. 3 illustrates a cross sectional view of a stator according to an embodiment of the present invention;

FIG. 4 illustrates a cross sectional view of a stator according to an embodiment of the present invention;

FIG. 5 illustrates a cooling channel of a stator according to an embodiment of the present invention;

FIG. 6 illustrates a cooling channel of a stator according to an embodiment of the present invention;

FIG. 7 illustrates a back iron lamination according to an embodiment of the present invention;

FIG. 8 illustrates a laminated back iron according to an embodiment of the present invention.

FIG. 1 and FIG. 2 illustrate an electric motor assembly incorporating an electric motor having a stator according to the present invention where the electric motor assembly includes built in electronics and is configured for use as a hub motor or in-wheel electric motor built to be accommodated within a wheel. However, the present invention could be incorporated in any form of electric motor. The electric motor can also be configured as a generator.

For the purposes of the present embodiment, as illustrated in FIG. 1 and FIG. 2, the in-wheel electric motor includes a stator assembly 252 and a rotor assembly 240. The stator assembly 252 comprising a heat sink 253 having a cooling channel, a laminated back-iron (not shown), multiple coils 254, an electronics module 255 mounted in a rear portion of the stator for driving the coils, and a capacitor (not shown) mounted on the stator within a recess 257 formed on the rear portion of the stator. In a preferred embodiment the capacitor is an annular capacitor element.

Stator tooth laminations are formed on the laminated back-iron, with the coils 254 being formed on the stator tooth laminations to form coil windings. A stator cover 256 is mounted on the rear portion of the stator 252, enclosing the electronics module 255 to form the stator assembly 252, which may then be fixed to a vehicle and does not rotate relative to the vehicle during use.

The electronics module 255 includes two control devices 400, where each control device 400 includes an inverter and control logic, which in the present embodiment includes a processor, for controlling the operation of the inverter.

To reduce the effects of inductance on the inverters, housed in the electronics module 255, when switching current, the capacitors mounted on the stator is used as a local voltage source for the electric motor inverters. By placing a capacitor close to an inverter the inductance associated with the voltage source is minimised.

A rotor 240 comprises a front portion 220 and a cylindrical portion 221 forming a cover, which substantially surrounds the stator assembly 252. The rotor includes a plurality of permanent magnets 242 arranged around the inside of the cylindrical portion 221. For the purposes of the present embodiment 32 magnet pairs are mounted on the inside of the cylindrical portion 221. However, any number of magnet pairs may be used.

The magnets are in close proximity to the coil windings on the stator 252 so that magnetic fields generated by the coils interact with the magnets 242 arranged around the inside of the cylindrical portion 221 of the rotor assembly 240 to cause the rotor assembly 240 to rotate. As the permanent magnets 242 are utilized to generate a drive torque for driving the electric motor, the permanent magnets are typically called drive magnets.

The rotor 240 is attached to the stator 252 by a bearing block 223. The bearing block 223 can be a standard bearing block as would be used in a vehicle to which this motor assembly is to be fitted. The bearing block comprises two parts, a first part fixed to the stator and a second part fixed to the rotor. The bearing block is fixed to a central portion 253 of the wall of the stator 252 and also to a central portion 225 of the housing wall 220 of the rotor 240. The rotor 240 is thus rotationally fixed to the vehicle with which it is to be used via the bearing block 223 at the central portion 225 of the rotor 240. This has an advantage in that a wheel rim and tyre can then be fixed to the rotor 240 at the central portion 225 using the normal wheel bolts to fix the wheel rim to the central portion of the rotor and consequently firmly onto the rotatable side of the bearing block 223. The wheel bolts may be fitted through the central portion 225 of the rotor through into the bearing block itself. With both the rotor 240 and the wheel being mounted to the bearing block 223 there is a one to one correspondence between the angle of rotation of the rotor and the wheel.

FIG. 2 shows an exploded view of the same assembly as FIG. 1 from the opposite side showing the stator assembly 252 and rotor assembly 240. The rotor assembly 240 comprises the outer rotor wall 220 and circumferential wall 221 within which magnets 242 are circumferentially arranged. As previously described, the stator assembly 252 is connected to the rotor assembly 240 via the bearing block at the central portions of the rotor and stator walls.

A V shaped seal is provided between the circumferential wall 221 of the rotor and the outer edge of the stator.

The rotor also includes a set of magnets 227 for position sensing, otherwise known as commutation magnets, which in conjunction with sensors mounted on the stator allows for a rotor flux angle to be estimated. The rotor flux angle defines the positional relationship of the drive magnets to the coil windings. Alternatively, in place of a set of separate magnets the rotor may include a ring of magnetic material that has multiple poles that act as a set of separate magnets.

To allow the commutation magnets to be used to calculate a rotor flux angle, preferably each drive magnet has an associated commutation magnet, where the rotor flux angle is derived from the flux angle associated with the set of commutation magnets by calibrating the measured commutation magnet flux angle. To simplify the correlation between the commutation magnet flux angle and the rotor flux angle, preferably the set of commutation magnets has the same number of magnets or magnet pole pairs as the set of drive magnet pairs, where the commutation magnets and associated drive magnets are approximately radially aligned with each other. Accordingly, for the purposes of the present embodiment the set of commutation magnets has 32 magnet pairs, where each magnet pair is approximately radially aligned with a respective drive magnet pair.

A sensor, which in this embodiment is a Hall sensor, is mounted on the stator. The sensor is positioned so that as the rotor rotates each of the commutation magnets that form the commutation magnet ring respectively rotates past the sensor.

As the rotor rotates relative to the stator the commutation magnets correspondingly rotate past the sensor with the Hall sensor outputting an AC voltage signal, where the sensor outputs a complete voltage cycle of 360 electrical degrees for each magnet pair that passes the sensor.

For improved position detection, preferably the sensor includes an associated second sensor placed 90 electrical degrees displaced from the first sensor.

The motor in this embodiment includes two coil sets with each coil set having three coil sub-sets that are coupled in a wye configuration to form a three phase sub-motor, resulting in the motor having two three phase sub-motors. However, although the present embodiment describes an electric motor having two coil sets (i.e. two sub motors) the motor may equally have one or more coil sets with associated control devices (i.e. the electric motor can be configured as a single motor or a plurality of sub motors). For example in a preferred embodiment the motor includes eight coil sets with each coil set 60 having three coil sub-sets that are coupled in a wye configuration to form a three phase sub-motor, resulting in the motor having eight three phase sub-motors.

FIGS. 3 to 6 illustrates a preferred embodiment of the stator heat sink 253, for providing cooling to a plurality of different electric motor components. However, the stator heat sink can take any form that allows the provision of cooling to the laminated back iron.

FIG. 3 illustrates a cross sectional view of the stator heat sink 253, where a cooling channel 300 is formed in a circumferential portion of the stator heat sink 253. Coolant is arranged to flow around the cooling channel 300, as described below.

The cooling channel 300 is arranged to have a first portion 310 that is orientated to be substantially perpendicular to a second portion 320 of the cooling channel 300. The first portion 310 and second portion 320 form a single cooling channel 300, where coolant is arranged to flow through the first portion 310 and the second portion 320. Additionally, the first portion 310 and second portion 320 are coupled to allow coolant to flow between the first portion 310 and second portion 320.

As illustrated in FIG. 4, one side of the first portion 310 of the cooling channel 300 is arranged to extend adjacent to a first surface 410 of the stator heat sink 253.

A second side of the first portion 310 of the cooling channel 300 is arranged to extend adjacent to a second surface 420 of the stator heat sink 253 upon which the control devices 400 are arranged to be mounted, as illustrated in FIG. 4.

Additionally, one side of the second portion 320 of the cooling channel 300 is arranged to extend adjacent to a third surface 430 of the stator heat sink 253. The stator teeth and coil windings 254 are arranged to be mounted on the third surface 430, as illustrated in FIG. 4.

A second side of the second portion 320 of the cooling channel 300 is arranged to extend adjacent to a fourth surface 440 of the stator heat sink 253, where the fourth surface 440 forms one side of the recess 257 for housing the capacitor 450, as illustrated in FIG. 4.

Accordingly, the preferred embodiment of the heat sink 253 provides a cooling arrangement having a cooling channel arranged to cool the electrical coils 254, a first electrical device (i.e. the control devices 400) and a second electrical device (i.e. the capacitor 450).

To illustrate a preferred configuration for the cooling channel 300, FIG. 5 represents a preferred embodiment of a cooling channel moulding 500 used to form a cooling channel 300 within a stator heat sink 253. Preferably, the stator heat sink 257 is formed using a sand casting process, where the cooling channel moulding 300 is formed from sand and cast onto the laminated back iron, as described below. However, any suitable form of casting may be used.

As would be appreciated by a person skilled in the art, the solid sections of the cooling channel moulding 500 correspond to the sections of the cooling channel within which coolant is able to flow within the stator heat sink 253.

Correspondingly, the gaps formed within the cooling channel moulding 500 correspond to solid sections within the cooling channel 300 in which coolant is unable to flow.

Feature A on the cooling channel moulding 500 corresponds to the cooling channel inlet, where cooling fluid is input into the cooling channel. Within the stator heat sink 253, the coolant travels around the orthogonal oriented sections of the cooling channel 300, which corresponds to the first portion 310 and second portion 320 of the cooling channel 300, in a clockwise direction based on the orientation of the cooling channel moulding illustrated in FIG. 5.

Feature B on the cooling channel moulding 500 corresponds to the cooling channel outlet, where cooling fluid is output from the cooling channel 300.

The dimensions of the inlet section of the cooling channel 300 are preferably configured to determine the amount of cooling fluid that is directed to circulate in the respective first portion 310 and second portion 320 of the cooling channel 300. For example, protrusions within the cooling channel inlet may be used to set the required percentage of cooling fluid to be circulated within the respective first portion 310 and second portion 320 of the cooling channel 300. By way of illustration, if a greater amount of cooling is required in the second portion of the cooling channel, that is to say the cooling channel portion sandwiched between the capacitor 450 and the bottom of the laminated back iron, protrusions within the cooling channel inlet can be used to send the majority of the coolant along this portion of the cooling channel 300.

The amount of coolant that flows between the first portion 310 and the second portion 320 of the coolant channel 300 is minimised by including a number of protrusions 510 at the interface between the first portion 310 and the second portion 320 of the cooling channel 300, as illustrated in

FIG. 5. The protrusions 510 act as an obstacle to the coolant flow between the first portion 310 and second portion 320 of the coolant channel 300 and accordingly inhibit the movement of coolant fluid between the two portions 310, 320, thereby allowing a single coolant channel to be used but where the amount of coolant in the separate portions 310, 320 can be independently controlled.

Preferably the effectiveness of the protrusions 510 may be enhanced by extending them to form a rib 520, as illustrated in FIG. 6, to cover more substantial portions of the cooling channel.

As the flow of coolant in the first portion 310 and the second portion 320 of the coolant channel 300 are effectively independent the cross sectional areas of the first portion 310 and second portion 320 of the cooling channel 300 can be independently selected depending upon the cooling needs associated with the different cooling channel portions. For example, if increased cooling is required the cross sectional area can be reduced to increase fluid flow. However, preferably for the present embodiment fluid flow is kept below five meters per second to minimise the risk of erosion of the stator heat sink 253.

To further fine tune the cooling characteristics of the first portion 310 and second portion 320 of the cooling channel 300 the cross sectional areas of different sections within the first portion 310 and/or second portion 320 can be changed depending upon specific cooling requirements. For example, as each of the two control device 400 mounted on the stator heat sink 253 only extend around a quarter of the stator heat sink circumference, to enhance cooling over the sections of the stator heat sink 253 upon which are mounted the control devices 400, the cross sectional area of the first portion 310 of the cooling channel 300 at these locations can be reduced relative to the sections of the first portion 310 at which the control devices 400 are not mounted, thereby increasing the cooling capability of the stator heat sink 253 at the positions where the control device 400 are mounted.

Accordingly, based on the cooling requirements it is possible to not only vary the amount of cooling between the first portion 310 and the second portion 320 of the cooling channel 300 but to also to vary the amount of cooling around both the first portion 310 and the second portion 320 of the cooling channel 300.

A further method of increasing the amount of cooling provided by the stator heat sink 253 is to increase the surface area of the first and/or second portion of the cooling channel. One method to provide increased surface area at targeted locations, for example under the control devices 400, would be to incorporated cooling ribs 530, as illustrated in FIG. 6.

Although the present embodiments, describe a single cooling channel having orthogonally oriented portions that are configured to provide optimum cooling to separate elements of the electric motor and associated control system, the electric motor may also include additional cooling channels for cooling other components, where the additional cooling channels may be of conventional design or as described above.

FIG. 7 illustrates a view of the laminated back-iron 700, where the laminated back-iron 700 is constructed from a plurality of individual laminations 710, where an individual lamination 710 is illustrated in FIG. 8, as is well known to a person skilled in the art.

Individual laminations may be joined together by any suitable means, for example by welding, adhesive bonding and mechanical joints such as cleating and interlocking.

Preferably the laminations 710 are made from electrical steel, typically having a small hysteresis area and high permeability.

Each lamination 710 has a plurality of inner protrusions 720 located on the inner radial surface of the lamination that extend radially inwards from the inner radial surface. The inner protrusions 720 act as a keying feature when interfaced with the stator heat sink 253, as described below. Keying features are features that allow for an increase in surface area of a surface that preferably provide for an increase in mechanical adhesion to a feature that is cast onto the keying feature.

Although the size and position of the inner protrusions may be randomly positioned and sized on the inner surface, preferably, and for the purposes of the present embodiment the inner protrusions 720 are equally spaced with respect to adjacent inner protrusions 720 and have substantially the same dimensions, as illustrated in FIG. 8. Typically, the size and position of the protrusions would be determined by factors such as the number and thickness of laminations, the number of teeth, the diameter of the back iron and the thickness of the stator wall. Preferably, to minimise the impact of the protrusions on the magnetic circuit of the electric motor, the protrusions are arranged to have the same symmetry as the stator teeth, with the protrusions positioned midway between each of the stator teeth.

As illustrated in FIG. 7 and FIG. 8, each lamination 710 additionally has a plurality of outer protrusions 730 located on the outer radial surface of the lamination 710. As illustrated, the outer protrusions 730 are equally spaced with respect to adjacent outer protrusions 730 and have substantially the same dimensions. When the individual laminations 710 are combined to form the laminated back iron 700, the outer protrusions 730 on the individual laminations 710 are oriented with respect to each other to form corresponding protrusions that extend three dimensionally in an axial direction on the laminated back iron 700, where the outer protrusions formed on the laminated back iron 700 are arranged to receive a stator tooth (not shown), for example, as described in patents GB2477520 and GB2507072. The inner protrusions 720 on the individual laminations 710 are combined to form a keying pattern on the inner surface of the laminated back iron 700.

Although the present embodiment describes a stator back iron 700 having a plurality of outer protrusions 730, where each protrusion is arranged to receive a stator tooth, equally, the outer protrusions may be configured to form stator teeth that are integral to the stator back iron 700.

Although the inner protrusions 720 on the individual laminations 710 can be oriented with respect to each other to form corresponding protrusions that extend three dimensionally in an axial direction on the laminated back iron 700, preferably to provide different keying structures for improved retention of the stator heat sink 253 to the laminated back iron 700, the inner protrusions 720 on the individual laminations 710 are oriented at different angles with respect to each other to form different three dimensional keying structures on the inner surface of the laminated back iron 700, as illustrated in FIG. 8. Accordingly, in a preferred embodiment, all or some of the plurality of laminations 710 that form the back iron 700 are positioned at rotationally different angles with respect to each other, thereby forming keying features at different rotational positions along the axis of the back iron 700.

Accordingly, all the inner protrusions 720 on the individual laminations 710 can be oriented the same with respect to each other to form corresponding protrusions that extend three dimensionally in an axial direction on the laminated back iron 700 or all the inner protrusions 720 on the individual laminations 710 can be oriented differently with respect to each other to form a complex keying structure, or a combination of some of the individual laminations 710 can be oriented the same with respect to each other to form corresponding protrusions that extend three dimensionally in an axial direction on the laminated back iron 700 for a given distance then a different orientation is used for the next set of laminations for a given distance to create a keying structure that is in a different orientation to the initial keying structure.

For example, the keying structure on the inner axial portion of the inner surface of the laminated back iron 700 shown in FIG. 8 is made up of a number of adjacent back iron laminations 710 that have the same orientation. The next row of keying structures are similarly made up of a number of adjacent back iron laminations 710 that have the same orientation with respect to each other, but have a different orientation to the back iron laminations on the inner axial portion of the laminated back iron. The next row of keying structures has the same orientation as the inner axial portion of the inner surface of the laminated back iron.

Having a back iron lamination 710 that has symmetrically repeating keying elements provides the advantage of allowing a single back iron lamination design to be used to create a large number of different keying structures for a laminated back iron by merely using a suitable orientation for adjacent laminations 710, thereby reducing manufacturing costs while improving retention of a laminated back iron 700 to a stator heat sink 253.

Once a laminated back iron 700 has been assembled with an appropriate keying structure formed on the inner surface, the stator heat sink 253 is cast on to the inner surface of the laminated back iron 700. The casting process allows the material that forms the heat sink 253, in molten form, to solidify on the inner radial surface of the laminated back iron 700, thereby resulting in the outer radial surface of the stator heat sink 253, which interfaces with the inner radial surface of the laminated back iron, to have complementary keying features to the keying features formed on the inner radial surface of the laminated back iron 700. Any suitable means may be used to perform the casting process. 

1. A stator for an electric motor, the stator comprising a back-iron having a first surface and a heat sink, wherein the first surface of the back-iron includes a plurality of keying features arranged to retain the heat sink to the back-iron, wherein the heat sink is arranged to provide cooling to the back-iron via surface of the heat sink, and wherein the surface of the heat sink has complementary keying features to the plurality of keying features on the first surface that are formed by casting the heat sink on the first surface of the back-iron, wherein the back-iron is formed from a plurality of laminations of electrical steel, wherein each of the plurality of laminations of electrical steel includes at least one keying feature, and wherein the plurality of laminations that form the back-iron are positioned at rotationally different angles with respect to each other, thereby forming keying features at different rotational positions along the axis of the back-iron.
 2. A stator according to claim 1, wherein the casting of the heat sink onto the first surface of the back-iron includes allowing the heat sink material in molten form to solidify on the first surface of the back-iron.
 3. A stator according to claim 1, wherein the back-iron includes a plurality of stator teeth formed or mounted on a second surface of the back-iron.
 4. (canceled)
 5. A stator according to claim 1, wherein the first surface of the back-iron is a circumferential inner surface of the back-iron formed from the circumferential inner surface of the plurality of laminations of electrical steel.
 6. A stator according to claim 5, wherein each of the plurality of laminations is substantially identical.
 7. (canceled)
 8. A stator according to claim 1, wherein the at least one keying feature of the plurality of laminations of electrical steel are arranged to extend radially inwards from the first circumferential surface of the laminations.
 9. (canceled)
 10. A method of manufacturing a stator, the method comprising: casting a heat sink onto a first surface of a back-iron, wherein the first surface of the back-iron includes a plurality of keying features arranged to retain the heat sink to the back-iron; forming the back-iron from a plurality of laminations of electrical steel, wherein each of the plurality of laminations of electrical steel includes at least one keying feature; and positioning the plurality of laminations that form the back-iron at rotationally different angles with respect to each other to allow keying features to be formed at different rotational positions along the axis of the back-iron.
 11. A method according to claim 10, wherein the step of casting of the heat sink onto the first surface of the back-iron includes allowing the heat sink material in molten form to solidify on the first surface of the back-iron.
 12. (canceled)
 13. (canceled) 